Vacuum cleaner

ABSTRACT

A vacuum cleaner includes a base and a brushroll positioned within the base. The base has a suction opening and is configured to move along a surface to be cleaned. The brushroll is rotatable relative to the base about an axis, and the brushroll includes a first end, a second end, an inflection point located between the ends, and a material that protrudes radially away from the brushroll. The material extends between the first end and the second end and wraps around the brushroll with a pitch. The material wraps in a first direction between the first end and the inflection point and wraps in a second direction between the inflection point and the second end.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. application Ser. No.16/582,381, filed Sep. 25, 2019, which claims priority to U.S.Provisional Patent Application No. 62/741,440 filed on Oct. 4, 2018, theentire content of which is incorporated herein by reference.

BACKGROUND

The present subject matter relates to vacuum cleaners and moreparticularly to brushrolls for vacuum cleaners.

SUMMARY

In one embodiment, a vacuum cleaner includes a base and a brushrollpositioned within the base. The base has a suction opening and isconfigured to move along a surface to be cleaned. The brushroll isrotatable relative to the base about an axis, and the brushroll includesa first end, a second end, an inflection point located along the axisbetween the first end and the second end, and a first material thatprotrudes in a radial direction away from the brushroll. The firstmaterial, having a first width, extends between the first end and thesecond end and wraps around the brushroll with a pitch relative to theaxis. The first material wraps in a first direction between the firstend and the inflection point and wraps in a second direction between theinflection point and the second end. The pitch of the first materialthat wraps in the first direction is opposite to the pitch of the firstmaterial that wraps the second direction.

In another embodiment, a vacuum cleaner includes a base and a brushrollpositioned within the base. The base has a suction opening and isconfigured to move along a surface to be cleaned. The brushroll isrotatable relative to the base about an axis, and the brushroll includesa body, a first end, a second end, an inflection point located along theaxis between the first end and the second end, a wall that extends in aradial direction away from the body, and grooves along the wall. Thewall follows a sloped path around the brushroll between the first endand the second end and wraps around the brushroll about the axis. Thedirection of the sloped path around the body reverses at the inflectionpoint. The grooves along the wall extend along a length of the brushrollbetween the first end and the second end and are spaced around acircumference of the brushroll.

In yet another embodiment, a vacuum cleaner includes a base, a brushrollthat is removable from and insertable into the base, and an aperturethough which the brushroll is removed and inserted. The base has asuction opening and is configured to move along a surface to be cleaned.The brushroll is rotatable relative to the base about an axis, and thebrushroll includes a body, a first end, and a second end. The apertureincludes teeth that are spaced around a circumference of the aperture.The teeth protrude parallel with axis and away from the aperture towardsthe brushroll. The teeth of the aperture align with the body of thebrushroll to collect debris from the brushroll as the brushroll is beingremoved from the base through the aperture.

Other aspects of the present subject matter will become apparent byconsideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vacuum cleaner according to anembodiment of the present disclosure.

FIG. 2 is a perspective view of a base of the vacuum cleaner of FIG. 1 .

FIG. 3 is a bottom perspective view of the base of FIG. 2 .

FIG. 4 is a bottom perspective view of the base illustrating innercomponents of the base.

FIG. 5 is a perspective view of the base illustrating a brushrollpartially removed from the base.

FIG. 6 is a front perspective view of a portion of the base illustratinga cap removable from the base.

FIG. 7 is a rear perspective view of a portion of the base illustratingthe cap of FIG. 6 .

FIG. 8 is a top view of the brushroll of FIG. 5 .

FIG. 9 is a front view of the brushroll of FIG. 5 .

FIG. 10 is an exploded perspective view of the brushroll and a portionof the base.

FIG. 11 is a cross-sectional view of the brushroll and a portion of thebase taken through the center of the brushroll.

FIG. 12 is a left-side view of the brushroll.

FIG. 13 is a right-side view of the brushroll and a portion of the base.

FIG. 14 is a right-side view of the brushroll.

Before any embodiments of the present subject matter are explained indetail, it is to be understood that the present subject matter is notlimited in its application to the details of construction and thearrangement of components set forth in the following description orillustrated in the following drawings. The present subject matter iscapable of other embodiments and of being practiced or of being carriedout in various ways.

DETAILED DESCRIPTION

FIG. 1 illustrates a vacuum cleaner 10 according to an embodiment of thepresent disclosure. The vacuum cleaner 10 includes a handle 11, a floornozzle or base 12, and a shaft 13 for connecting the handle 11 to thebase 12. The base 12 includes a housing 14 and a brushroll or beater bar16 that rotates relative to the base 12 about an axis 17 (FIG. 2 ) thatextends along a length of the brushroll 16 and through a center of thebrushroll 16. In the illustrated embodiment, the base 12 includes awindow 18 that allows the user to view the brushroll 16 within the base12. The window 18 may be transparent, or semi-transparent, in somecases.

Referring to FIG. 2 , the brushroll 16 includes a body 20 that has afirst end 20A, a second end 20B, and an inflection point 20Csubstantially in the middle of the first end 20A and the second end 20B.The details of the inflection point 20C are described further below. Thebody 20 may be formed, at least partially, from a rubber or plasticmaterial in some embodiments. The body 20 may include a plurality ofgrooves 22, a wall 23, a first recess 24 for receiving a first cleaningmaterial 24A, a second recess 25 for receiving a second cleaningmaterial 25A, and a third recess 26 for receiving a third cleaningmaterial 26A. As used herein, the term cleaning material refers tomaterials configured for cleaning, such as, for example, a textile(e.g., woven, non-woven materials) configured for cleaning, a specificfabric configured for cleaning, a bristle configured for cleaning, afoam material configured for cleaning, an electrostatic materialconfigured for cleaning, and/or the like. The grooves 22 may extend intothe wall 23 along the length of the body 20 between the first end 20Aand the second end 20B. The brushroll 16 additionally comprises acircumference C (FIG. 12 ) and the grooves 22 may be spaced evenlyaround the circumference C. Unevenly spaced grooves 22 are alsocontemplated. In some embodiments, the first, second and third recess24, 25, 26 all receive a first type (i.e., a same type) of material. Inthe illustrated embodiment, the first recess 24 receives the firstmaterial 24A, and the second and third recesses 25, 26 receive thesecond material 25A. In yet another embodiment, the first, second, andthird cleaning materials 24A, 25A, and 26A are received and/or attacheddirectly on the body 20 of the brushroll 16 and connected with afastener (e.g., a glue, an adhesive, a hook and loop fastener, and/orthe like).

With continued reference to FIG. 2 , the first recess 24 has a firstwidth 27 (FIG. 8 ) and follows a V-shaped path that extends or wrapsaround the circumference C of the body 20. The second and third recesses25, 26 each have a second width 28 (FIG. 8 ). The first width 27 (see,e.g., FIGS. 8 and 12 ) is a length of an arc extending between a top andbottom of the first recess 24 along a line normal to the axis 17. Thesecond width 28 (shown in FIGS. 8 and 12 ) is a length of an arcextending between a top and bottom of the second and/or third recesses25 and 26 along a line normal to the axis 17. The second width 28 may berelatively narrow compared to the relatively wide first width 27. Thesecond and third recesses 25, 26 may be located on opposite sides of thefirst recess 24. The first recess 24 may be disposed between the secondrecess 24 and third recess 26 and each of the recesses 24, 25, 26 mayfollow and/or be formed as a V-shaped path.

In the illustrated embodiment, the path of the first material 24A may besubstantially the same as the path of the first recess 24, the path ofthe second material 25A may be substantially the same as the path of thesecond recess 25, and the path of the third material 26A may besubstantially the same as the path of the third recess 26. In anotherembodiment, the first, second and third material 24A, 25A, 26A may bereceived directly on the body 20 of the brushroll 16 and connected witha fastener rather than received in a first, second, or third recesses24, 25, 26, respectively.

Referring now to FIGS. 2-4 of the illustrated embodiment, the firstmaterial 24A may be formed from a plush cloth material. Other materials(e.g. non-plush materials) may also be used as the first material 24A insome embodiments. The second material 25A may include and/or be formedas a row of bristles. The third material 26A may include a row ofbristles. The second and third materials 25A and 26A may includedifferent types of bristles (e.g., bristles having different lengths,diameters, and/or the like) and/or bristles comprised of differentmaterials. In one embodiment, the bristles may include and/or be formedas nylon bristles. The first material 24A may include a first length andis configured for collecting a first type of debris (e.g., dirt, dust,powder, glitter, particulates, and/or the like). The second and thirdmaterial 25A, 26A may have a second length that is greater than thefirst length and are configured for collecting a second type of debris(e.g., hair, hay, thread, string, and/or the like).

The details regarding the inflection point 20C will now be describedwith reference to the V-shaped path. In some embodiments, the inflectionpoint 20C lies along the axis 17 and is about equidistant between thefirst end 20A and the second end 20B. The first material 24A protrudesin a radial direction away from the brushroll 16 and extends between thefirst end 20A and the second end 20B. The path of the first material 24Awraps around the brushroll 16 with a pitch P (FIG. 9 ) relative to theaxis 17. Between the first end 20A and the inflection point 20C, thepath of the first material 24A wraps in a first direction (i.e.,clockwise). Between the inflection point 20C and the second end 20B, thepath of the first material 24A wraps in a second direction (i.e.,counter-clockwise). At the inflection point 20C, the pitch P of the pathof first material 24A wrapping in the clockwise direction flips suchthat the pitch P of the path of first material 24A wrapping in thecounter-clockwise direction is equal and opposite, or substantiallyequal and opposite.

In the illustrated embodiment, the V-shaped path extends between thefirst end 20A and the second end 20B, and the inflection point 20Crepresents the tip of the letter “V” where the V-shaped path changesdirection. The first, second, and third recesses 24, 25, 26 and thefirst, second, and/or third materials 24A, 25A, 26A disposed in therecesses may each follow the V-shaped path as described in theillustrated embodiment. In the illustrated embodiment, each of thefirst, second, and third recesses 24, 25, 26 are duplicated at leastonce around the brushroll 16. In another embodiment, the first, second,and third recess 24, 25, 26 are duplicated multiple times around thebrushroll 16.

The illustrated brushroll 16 further includes the wall 23 which extendsin a radial direction away from the body 20 and follows a sloped patharound the brushroll 16. The wall 23 extends between the first end 20Aand the second end 20B and wraps around the brushroll 16 about the axis17. The direction of the sloped path about the axis 17 reverses at theinflection point 20C. The sloped path of the wall 23 substantiallyfollows the path of the first material 24A around the brushroll 16. Thesloped path has the pitch P angle that remains constant as the wall 23wraps clockwise around the brushroll 16 between the first end 20A andthe inflection point 20C. At the inflection point 20C, the pitch P anglechanges by about 90 degrees relative to the axis 17. As the wall 23wraps counter clockwise around the brushroll 16 between the inflectionpoint 20C and the second end 20B, the pitch P angle remains constant.The wall 23 between the first end 20A and the inflection point 20C issubstantially the same as the wall 23 between the inflection point 20Cand the second end 20B when mirrored across the inflection point 20Calong the axis 17. In the illustrated embodiment, an entire outersurface of the body 20 is covered by the first material 24A, secondmaterial 25A, third material 26A and the wall 23. Meaning that when thematerials 24A, 25A, 26A are received on the brushroll 16, none of theouter surface of the body is exposed. In another embodiment, some of thebody 20 (e.g., a portion of the body 20) is exposed or uncovered. In yetanother embodiment, the entire outer surface of the body 20 is coveredby only the first material 24A and the wall 23.

FIGS. 8 and 9 illustrate the brushroll 16 with the first, second, andthird material 24A, 25A, 26A removed from the brushroll 16 to reveal thebody 20, grooves 22, wall 23 and the first, second, and third recess 24,25, 26. FIGS. 8 and 9 illustrate the wall 23 and the first, second, andthird recesses 24, 25, 26 each following substantially the same V-shapedpath. The wall 23 starts at one point of, on, or around thecircumference C of the brushroll 16 and the first recess 24 starts at adifferent point of, on, or around the circumference C of the brushroll16. A third width 72 (shown in FIGS. 8 and 12 ) is a width of the wall23. The third width 72 is an arc having a length between a top andbottom of the wall 23 along a line normal to the axis 17. The firstwidth 27, second width 28 and third width 72 may each remainsubstantially consistent regardless of where the width is being measuredalong the axis 17, in some embodiments.

Referring now to FIGS. 3 and 4 , the base 12 may additionally includewheels 30, support rollers 34, a motor 38, a driving mechanism 42, asuction opening 44, a suction inlet 46 and roller support assembly 48.The wheels 30 and the support rollers 34 enable the base 12 to be movedalong a surface to be cleaned. The handle 11 of FIG. 1 includes a powersource 50 operable to generate a suction airflow through the vacuumcleaner 10. The suction airflow is brought in to the base 12 through thesuction opening 44 and enters the vacuum cleaner 10 through the suctioninlet 46. In another embodiment the power source 50 is located in thebase 12. With specific reference to FIG. 4 of the illustratedembodiment, the motor 38 rotates the drive mechanism 42 for rotating thebrushroll 16.

With reference to FIGS. 5-7 , the base 12 of the illustrated embodimentfurther includes a cap or cover 54. The cover 54 may be removablyattached to the housing 14. The cover 54 includes a cover handle 58 thatcan be grabbed by a user using their thumb and index finger in onemethod of operation. In one embodiment, the cover 54 may be rotated(e.g. about one-quarter turn) relative to the housing 14 by the user torelease or unlock the cover 54. This allows the user to pull the cover54 away from the base 14 to access and remove the brushroll 16. FIGS. 6and 7 illustrate the housing 14 further including an aperture 60 and aradial groove 62 and the cap 54 including a tab 66. The tab 66corresponds to the radial groove 62 for interlocking the cap 54 to thehousing 14 and thereby securing the brushroll 12 in the housing 14.

With continued reference to FIGS. 6 and 7 , the aperture 60 may besubstantially circular and include teeth 70 that are spacedcircumferentially around the aperture 70. The teeth 70 may protrude awayfrom the aperture in a direction toward the second end 20B of thebrushroll 16 and parallel to the axis 17. The teeth 70 are configured toalign with the spacing of the grooves 22 along the brushroll 16 tocollect debris (e.g., hair, dirt, dust, and/or the like) as thebrushroll 16 is being removed from the base 12 through the aperture 60.In another embodiment, the teeth 70 need not align with the grooves 22to collect debris. In yet another embodiment, the body 20 may notinclude the grooves 22 and the teeth 70 still collect debris. The teeth70 each have a similar size and shape that correspond with a similarsize and shape of the grooves 22. In the illustrated embodiment, theteeth 70 also collect debris as the brushroll 16 is being used. Theteeth 70 are also configured to collect elongated debris that wouldotherwise be missed by the brushroll 16. In this way, the brushroll 16may be more easily cleaned and/or maintained. The grooves 22 alsoprovide a guide or path for a knife, scissors or other cuttinginstrument to glide over and remove hair or other debris. The user canmove the cutting instrument along the grooves 22 while the grooves 22guide the movement to cut or otherwise loosen any debris, includinghair, which is wrapped around or on the brushroll 16.

In some embodiments, the cover 54 is attached to the brushroll 16 sothat the cover 54 may be pulled to pull the brushroll 16 through theaperture 60. That is, the brushroll 16 may be removed along with thecover 54. In such an embodiment, the cover 54 may be rotatable withinthe aperture 60 relative to the brushroll 16 to align with the radialgroove 62 to lock and unlock the cover 54 from the housing 14.

Referring now to FIGS. 10-14 of the illustrated embodiment, the base 12further includes an end cap 74 located at the second end 20B of thebrushroll 16. The end cap 74 may be chamfered or angled toward thebrushroll 16 and covers bearing 78 that facilitates rotation of thebrushroll 16. The angled or chamfered end cap 74 has been found tominimize the amount of hair and other debris that interferes withrotation of the brushroll 16 and the bearing 78.

The housing 14 may additionally include a plug 82, and a gear 86. Theplug 82 includes slots 90 that engage with internal blades 94 of thebrushroll 16 such that the plug 82 rotates with the brushroll 16. In theillustrated embodiment, the plug 82 further includes a circular opening98 for receiving a shaft 102 connected to the cover 54 and the circularopening 98 includes a stopper 106 for preventing the cap 54 from beingremoved from the plug 82. In another embodiment, the cover 54 may beseparated from the plug 82. In still another embodiment, the plug 82 isfixed to the brushroll 16 and the cover 54 is fixed to the plug.

The gear 86 includes gear teeth 110 that engage with roller teeth 114 onthe inside of the brushroll 16. The gear 86 is driven by the drivingmechanism 42 which rotates the gear teeth 110 to engage the roller teeth114 to rotate the brushroll 16 relative to the base 12.

Although the present subject matter has been described in detail withreference to certain preferred embodiments, variations and modificationsexist within the scope of one or more independent aspects of the subjectmatter as described.

What is claimed is: 1-20. (canceled)
 21. A base of a vacuum cleaner, comprising: a housing having a suction opening, the base being configured to move along a surface to be cleaned; and a brushroll removable from and insertable into the housing and rotatable about an axis, the brushroll including a body, a first end, and a second end opposite the first end, wherein the housing includes an aperture defined by a cylindrical inner surface through which the brushroll is removable, wherein a plurality of teeth are spaced around the cylindrical inner surface and extend into the aperture defined by the cylindrical inner surface, wherein the plurality of teeth protrude radially inward from the cylindrical inner surface and subsequently protrude parallel with the axis and towards the brushroll located within the housing, and wherein the plurality of teeth are configured to collect debris from the brushroll when the brushroll is removed from the housing through the aperture.
 22. The base according to claim 21, wherein each of the plurality of teeth defines a radial portion that extends radially inward from the cylindrical inner surface and an axial portion that extends axially towards the brushroll in the housing from the radial portion, and wherein a terminal end of the radial portion has the same width as a base end of the axial portion.
 23. The base according to claim 22, wherein a terminal end of the axial portion is narrower than the base end of the axial portion.
 24. The base according to claim 21, wherein the body of the brushroll includes a wall and a plurality of grooves that extend into the wall along a length of the body between the first end and the second end.
 25. The base according to claim 24, further comprising a cleaning material received within a recess formed in the body of the brushroll.
 26. The base according to claim 24, wherein the plurality of teeth are axially spaced apart from the plurality of grooves of the brushroll when the brushroll is installed within the housing.
 27. The base according to claim 21, wherein the brushroll is removable through the aperture in a direction along the axis.
 28. The base according to claim 21, wherein the teeth are formed integrally with the base.
 29. The base according to claim 21, further comprising a handle coupled to the brushroll, positioned at the aperture, and configured to rotate relative to the aperture.
 30. The base according to claim 21, further comprising a handle coupled to the brushroll, positioned at the aperture, and configured to rotate relative to the plurality of teeth.
 31. A base of a vacuum cleaner, comprising: a housing having a suction opening, the housing being configured to move along a surface to be cleaned; and a brushroll removable from and insertable into the housing and rotatable about an axis, the brushroll including a body, a first end, and a second end opposite the first end, wherein the housing includes an aperture defined by a circumferential surface through which the brushroll is removable, wherein a plurality of teeth are spaced around the circumferential surface and protrude radially inward of the circumferential surface and subsequently protrude parallel with the axis towards the brushroll located within the housing, and wherein the plurality of teeth are configured to collect debris from the brushroll when the brushroll is removed from the housing through the aperture.
 32. The base according to claim 31, wherein each of the plurality of teeth defines a radial portion that extends radially inward from the circumferential surface and an axial portion that extends axially towards the brushroll in the housing from the radial portion, and wherein a terminal end of the radial portion has the same width as a base end of the axial portion.
 33. The base according to claim 32, wherein a terminal end of the axial portion is narrower than the base end of the axial portion.
 34. The base according to claim 31, wherein the body of the brushroll includes a wall and a plurality of grooves that extend into the wall along a length of the body between the first end and the second end.
 35. The base according to claim 34, further comprising a cleaning material received within a recess formed in the body of the brushroll.
 36. The base according to claim 34, wherein the plurality of teeth are axially spaced apart from the plurality of grooves of the brushroll when the brushroll is installed within the housing.
 37. The base according to claim 31, wherein the brushroll is removable through the aperture in a direction along the axis.
 38. The base according to claim 31, wherein the teeth are formed integrally with the base.
 39. The base according to claim 31, further comprising a handle coupled to the brushroll, positioned at the aperture, and configured to rotate relative to the aperture.
 40. The base according to claim 31, further comprising a handle coupled to the brushroll, positioned at the aperture, and configured to rotate relative to the plurality of teeth. 